Inner packaging with cohesive coating

ABSTRACT

Various embodiments of packaging containers and packaging materials are provided to limit movement of the packaging materials and a product within the packaging container during shipment or transportation of the packaging container. Movement is limited by cohering the packaging materials to the packaging container.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to packaging containers and inner packaging materials. The present invention more specifically relates to packaging containers and inner packaging materials that each has a cohesive coating disposed on a portion thereof.

2. Description of the Related Art

Many types of packaging techniques are used to prepare products for transport between locations. Because products within packaging containers may have a tendency to move during transportation, different types of inner packaging materials have been used to stabilize or protect products during transportation. For instance, inner packing materials such as foam pieces, paper, contoured foam pieces, inserts and the like are used to fill voids defined between the product placed in a container and the container itself.

Each of these packaging techniques has drawbacks. For instance, using the small foam pieces does not necessarily secure the produce from movement within the container. Moreover, while the foam pieces admit of reuse, they often are discarded by the receiver of packaging and are fairly bulky and difficult to contain during disposal.

Paper may also be used in a similar manner to the foam pieces. Following insertion of a certain amount of paper within the container and placement of the product therein, the remaining voids between the product and the packaging can be filled with additional paper. Such a technique can crush more delicate products, such as flowers, for instance. Moreover, such a technique can cause marring of the surface finish of some products due to relative movement of the paper and the product during transport.

Another manner for protecting products within packaging is by the use of bubble wrap. Bubble wrap may be wrapped around the product and secured in place before the product and the bubble wrap are placed within the packaging. Once the product is enclosed in bubble wrap, an appropriate packaging container is obtained into which the product and the bubble wrap are placed. Again, bubble wrap admits of being reused but often is simply discarded and not reused. The bubble wrap also comes in longer sheets, which limits the placement of the bubble wrap protection relative to the product and the bubble wrap does not necessary limit movement of the product relative to an outer container. Therefore, packaging with bubble wrap also has significant drawbacks.

In some applications, cohesive singleface may be used to protect products during transportation. Singleface is a flexible wrap that consists of a single liner and has a fluted medium attached to one side of the liner. A cohesive material is disposed on the single liner that permits the singleface to adhere to itself. Singleface is often wrapped around otherwise vulnerable parts of furniture to protect the parts from impact or scratches during transportation. Because of its construction, singleface is very flimsy and is not suitable to provide a support surface for products in common packaging. For instance, because of singleface's flimsy qualities, even if it were used in packaging, it would not adequately secure the product within the packaging container.

Yet another manner in which packaging materials are used to insulate and secure products within packaging is by the use of formed or molded structures that are designed for specific products and packaging. For example, one or several pieces of foam may be used or cooperate with each other to enclose or secure a product before placement of the product within the packaging. The formed foam components can be expensive to manufacture and often can only be used with one specific product in one specific container. Thus, an undesirably large variety of formed foam components may need to be manufactured for use by a single company and the expense.

Products also can be secured in place on an inner board or member using wires, strings or tape. This technique is often found in the packaging of children's toys, such as larger dolls or action figures. While the inner board or member limits movement of the product relative to the outer container, wires or strings mar more delicate surface finishes and tape leaves a residue on the surface of the product.

SUMMARY OF THE INVENTION

Due to the shortcomings of the above-mentioned packaging materials, there is a need for packaging material that is not easily displaced during transportation of the packaging, that is easy and cost effective to manufacture, that may be reusable and easily stored, and that is less likely to mar the finish of products or crush more delicate products.

Thus, certain features, aspects and advantages of the present invention relate to packaging materials and methods of using such packaging materials. The packaging materials feature at least a pair of components that each has a cohesively-coated surface. The cohesive surfaces are arranged and configured to cohere to each other without significant sticking to the product being shipped. The components preferably limit movement of the product relative to the container. Advantageously, the coherence of the components allows the components to be generally moveably secured together such that the components can be fixed in one position and may permit subsequent fixing in another position.

In one arrangement, a packaging assembly is provided that comprises a corrugated component and a film. The corrugated component comprises a liner, at least a portion of the liner having a first cohesive coating disposed thereon. The film has a second cohesive coating disposed on at least a portion thereof. The first and second cohesive coatings are complementary such that the first cohesive coating will cohere to the second cohesive coating. The film is secured to the corrugated component by the first and second cohesive coatings.

Another aspect of the present invention involves a shipping box comprising a plurality of walls formed of a corrugated material. The corrugated material comprises at least two liners and at least one medium positioned between the at least two liners. A portion of at least one of the plurality of walls is treated with a cohesive coating. An insert is provided that is sized and configured for placement within the shipping box. The insert is formed of a second corrugated material. The second corrugated material comprises at least two liners and at least one medium disposed between the at least two liners. The insert has a portion thereof treated with a cohesive coating that is complementary to the cohesive coating of the shipping box. When the cohesive coating of the insert is placed for contact with the cohesive coating on the shipping box, the insert can be secured in position relative to the shipping box and the insert may permit some repositioning within the shipping box without destroying either the shipping box or the insert.

A further aspect of the present invention involves a method of preparing a packaging container for shipment or transportation of the packaging container with a product therein. The method comprising providing a packaging container having an inner portion thereof treated with a cohesive coating; providing a packaging material having a portion thereof treated with a cohesive coating that is configured to cohere with the cohesive coating of the packaging container, and cohering the packaging material to the packaging container by contacting a portion of the cohesive coating on the packaging material with a portion of the cohesive coating on the packaging container such that the packaging material coheres with the packaging container.

For purposes of summarizing the invention, certain embodiments, advantages and features of the invention have been described herein. Of course, it is to be understood that not necessarily all such embodiments, advantages or features are required in any particular embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-identified features, aspects, and advantages of the present invention will now be described with reference to the drawings of several preferred embodiments, which embodiments are intended to illustrate and are not intended to limit the invention. The drawings comprise three figures.

FIG. 1 is a perspective view of a portion of a corrugated material having a cohesive outer layer, a product positioned on the material and a cohesive film securing the product in place on the material.

FIG. 2 is perspective view of a container having a cohesive inner layer formed on a piece of single wall corrugated paper.

FIG. 3 is a perspective view of an inner liner similar to that of the arrangement of FIG. 1 and shown using a piece of double wall corrugated paper.

FIG. 4 is a perspective view of a single wall inner liner similar to the double wall inner liner of FIG. 3. The inner liner can be used with film, air bags, or other structures, as indicated by the dashed lines A and B.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the figures, certain embodiments will be described, which embodiments provide packaging containers and packaging materials and the applications of such. The packaging containers and/or the packaging materials can be formed from corrugated paper. At least two components have cohesive layers formed on them such that the two components can be secured together by coherence of the cohesive layers.

As used herein, corrugated paper can have its ordinary meaning and shall mean components having a single wall construction, a double wall construction and the like. As used herein, single wall can have its ordinary meaning and can mean a product formed with a pair of liners separated by a medium that can be fluted or otherwise formed to space the liners apart from one another. As used herein, double wall can have its ordinary meaning and can mean a product formed with three liners separated by a pair of mediums that can be fluted or otherwise formed to space the three liners apart from one another.

As used herein, a cohesive layer can be formed by a cohesive material, which has can have its ordinary meaning and can mean a coating that is applied to a substrate and sticks to itself. In some arrangements, the cohesive material is a formulate rubber latex. In other arrangements, the cohesive material is a non-latex material. As such, various formulated coatings may be used for the cohesive coating. For example, formulated natural rubber latex may be used for the cohesive coating in one embodiment. In other embodiments, either latex or latex-free coatings may be used. For example, APILCS-C and APILCS-D industrial and medical grade sterilizable latex coatings may be used, or APILFCS-2 and APELFCS-5 medical grade sterilizable latex-free coatings may be used. The particular coating selected can vary depending upon design goals of the packaging. For instance, coatings that attach more securely to other coated surfaces than to the liner can be used in packaging where partial or complete destruction of the coated surface is desired (e.g., to show a product has been removed for the packaging) while coatings that attach more securely to the liner than to other coated surfaces can be used in packaging where reuse or reconfiguration is a priority (e.g., storage of differing products in the same container). As used herein, complementary cohesive coatings are coatings selected such that the two coatings are configured cohere together.

With reference now to FIG. 1, a first packaging assembly 10 is shown that is arranged and configured in accordance with certain features, aspects and advantages of the present invention. The assembly features a corrugated component 12 and a film 14. A liner 16 of the corrugated component 12 is shown and the fluted medium has been omitted from the drawing of FIG. 1.

The liner 16 preferably comprises a cohesive coating 20 that has been applied to at least a portion of the liner 16. The cohesive coating 20 can be applied to the entire surface of the liner 16 or can be applied to a select region or select regions of the liner 16, depending upon the application. As described above, the cohesive coating 20 can be any suitable material that sticks substantially only to itself. The coating 20 can be rolled onto the liner 16, can be sprayed onto the liner 16, can be painted onto the liner 16 or applied in any other suitable manner. In addition, the coating 20 can be applied to the liner 16 either before or after attachment of the liner to a medium to form a corrugated component. An advantage to coating after formation of the corrugated component is that the same stock can be used for coated and uncoated products. An advantage to coating before formation of the corrugated component is that the manufacturing process is simplified and the cost of manufacturing can be reduced. Coating before formation can be performed with certain corrugating machines, such as an AUSTRADE™ corrugating machine, for instance but without limitation.

The film 14 can have any suitable construction and is dependent upon the goals of the packaging. For instance, the film can be configured as an air bar, as a pouch, as a sheet, as a plurality of strips or straps or the like. Regardless of the structure, the film preferably is formed of a suitable polyethylene-based material although other materials can be used. The film 14 preferably comprises a cohesive coating 22 as well. The cohesive coating 22 allows the film 14 to stick to itself or to stick to the cohesive coating 20 that is present on the liner 16. The cohesive coating 20 can be applied to only one surface of the film 14. In some embodiments, the cohesive coating 20 can be applied to both surfaces of the film 14. Moreover, only portions of the film 14 can be coated in certain applications.

With continued reference to FIG. 1, a product 24 can be placed on the corrugated component 12 such that it is positioned on the liner 16. The product can be secured in position on the corrugated component 12 with the film 14. The cohesive coating 22 of the film 14 coheres with the cohesive coating 20 of the liner 16 such that the film is secured to the liner by cohesion. The product 24 is thereby secured in position relative to the corrugated component 12 and the film 14 does not adhere to the product 24 and is less likely to leave residue on the product or mar the finish of the product.

With reference now to FIG. 2, a packaging container 30 is illustrated. The packaging container 30 has a plurality of walls 32 that cooperate to create an enclosed inner portion within the packaging container 30. The packaging container 30 can be formed of any suitable material. In one arrangement, the walls 32 are formed of a double wall corrugated material. In the illustrated embodiment, the walls 32 are formed of a single wall corrugated material. Although the packaging container 30 in FIG. 2 is illustrated as a rectangular box, other shapes and designs of packaging containers may also be used. For example but without limitation, the packaging container 30 may be cylindrically or irregularly shaped.

The single wall corrugation that defines the illustrated walls 32 has an inner liner 34 that defines the inner enclosed portion of the packaging container 30. The inner liner 34 has at least a portion thereof with a cohesive coating 36. The cohesive coating 36 can cover the entire inner liner 34 or can be provided over only select portions of the inner liner 34.

The walls 32 also are shown with a corrugated medium 38 that consists of a medium having a plurality of ridges, or flutes 39. The liner 34 preferably is adhered to the flutes 39 and an outer liner 40 also preferably is adhered to the flutes 39 to define the single wall structure in the illustrated arrangement. The outer liner 40 in the illustrated arrangement preferably forms an outer surface 42 of the container 30.

Materials may be provided to increase the strength of the packaging container 30. For example, cohesive coated corrugated material may be placed on the interior or exterior of the packaging container 30 to increase the strength of localized portions of the walls 30 or other portions of the packaging container 30 (e.g., corners). Further, cohesive coated fiber wrap may also be placed on the walls 20 or other portions of the packaging container 20 to increase the strength of the packaging container 20.

With reference now to FIG. 3, a portion of a packaging insert 50 is shown. The illustrated insert 50 is formed of a double wall corrugated material. The double wall material has superior rigidity compared to single wall material. Importantly, both double wall material and single wall material has significantly more rigidity than a single face material (i.e., a liner backed only by a medium without a second liner attached). As illustrated, the insert 50 comprises a liner 52 that has a cohesive coating 54 disposed thereon. The illustrated insert 50 also comprises two layers of a corrugated medium 56 that is adhered to the liner 52 and a second liner 58. A liner 60 also is disposed between the two layers of medium 56.

The insert 50 can be secured or placed within a container in any suitable manner. In the illustrated arrangement, a support is secured to the inert 50 via a cohesive connection. For example, an angle board 62 may be provided a cohesive coating 64 which can cohere to a portion of the cohesive coating 54 of the insert 50. Such supports can be cohered to an inner surface of a packaging container, such as the container 30 shown in FIG. 2. In some embodiments, the supports simply rest within the packaging container and provide reinforcement or locating structure for the container and liner. For example, the angle board 62 may be placed within the packaging container 30 to increase the strength of the walls 32 to resist, for example, side impact failure. In other configurations, the insert can comprise surfaces that cohere to an inner surface of an outer packaging container such that the insert can be secured in desired locations within the outer packaging container. For instance, folded portions of the insert can be provided with a coated portion that coheres to the inside of the outer packaging container.

With reference now to FIG. 4, multiple embodiments of packaging and packaging materials are shown in arrangements that can configured in accordance with certain features, aspects and advantages of the present inventions. A liner 70 is provided having a cohesive coating 72 disposed thereon. The coating 72 can cover the entirety of the liner 70 or simply cover a surface of the liner 70. The liner 70 may be a portion of a wall or an insert that will be or has been placed within a packaging container.

A film 74 can be positioned on the liner 70 and secured thereto by cohesion. In other words, the film 74 preferably comprises a complementary cohesive coating 76. The film 74 can have any suitable configuration. In FIG. 4, the film 74 is shown configured as an air bag. In FIG. 1, the film 14 is shown configured in a sheet form. In FIG. 4, the film 74′ also is shown configured as a pouch. Any other suitable configuration also can be used. The cohesive coating 76 can be placed on selected portions of the film or can be placed on the entirety of the film.

With continued reference to FIG. 4, a product 78 or product box also is illustrated. In this configuration, the box can have a cohesive coating 80 disposed on at least a portion of its outer surface. The film pouch 74′ may be provided to cover the product 78 or product box. The film pouch 74′ may also have a cohesive coating 26 disposed on an inner surface such that the film pouch 74′ can cohere to the product 78 for shipping.

In one embodiment, as illustrated with respect to the dotted lines A in FIG. 4, the cohesive coating 80 on the product 78 or product box may be configured to cohere with the cohesive coating of the film 74 (e.g., air bag). Additionally, the film 74 (e.g., air bag) may be configured with a cohesive coating 76 on a portion thereof that is adjacent to the substrate liner 70 and the cohesive coating 72 disposed thereon. Accordingly, the product 78 or product box is configured to cohere to the packaging material 74, which in turn is configured to cohere with the liner 70. The cohesive coatings disposed between the liner 70 and the film 74 and the cohesive coating disposed between the film 74 and the product 78 or product box is configured to limit movement relative to each other.

In another embodiment, as illustrated by dotted lines B in FIG. 4, the product 78 or product box with the cohesive coating 80 disposed thereon may be configured to adhere directly to the liner 70 and the cohesive coating 72 disposed thereon.

In a further embodiment, the film 74′ (e.g., pouch) with the cohesive coating may be configured to enclose the product 78. The product 78 or product box may cohere to the pouch in some arrangements and may simply be received within the pouch in other arrangements. The film 74′ may be configured to cohere with the cohesive coating 76 on the packaging material 74 as illustrated with respect to dotted lines A, or the film 74′ may be configured to cohere to the cohesive coating 72 of the substrate 70, as illustrated with respect to the dotted lines B.

In another embodiment (not illustrated), a cohesive coating may be disposed on the exterior surface 42 of the walls 32 of the packaging container 30. The cohesive coating may be configured to permit cohesion of packaging containers 30 such that the packaging containers can be combined to lessen movement of the each of the containers individually, which reduces incidental contact among containers during shipping. This manner of shipping products may be used to reduce the likelihood of damage to the product within the shipping container 30 as well as other products and packages that are located near the packaging containers 30 during bulk shipment or transportation.

Although the above embodiments are described with respect to packaging containers made primarily of paper-based materials, it is contemplated that the principles disclosed herein may be applied to packaging containers made of other materials. For example, it is contemplated the cohesive coating may also be applied to packaging containers made of plastic or metal.

Although the present inventions have been disclosed in the context of certain preferred embodiments and exampled, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the present inventions and obvious modifications and equivalents thereof. In addition, while a number of variations of the present inventions have been shown and described in detail, other modifications, which are within the scope of the present inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the present inventions. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the present inventions. Thus, it is intended that the scope of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above. 

1. A packaging assembly comprising: a corrugated component comprising at least two liners, at least a portion of at least one of said liners having a first cohesive coating disposed thereon; and a film having a second cohesive coating disposed on at least a portion thereof, said first and second cohesive coatings being complementary such that said first cohesive coating will cohere to said second cohesive coating and said film being secured to said corrugated component by said first and second cohesive coatings.
 2. The packaging container of claim 1, wherein said corrugated component comprises a single wall construction.
 3. The packaging container of claim 1, wherein said corrugated component comprises a double wall construction.
 4. The packaging container of claim 1, wherein said film is configured as an air bag.
 5. The packaging container of claim 1, wherein said film is configured as a sheet.
 6. The packaging container of claim 1, wherein said film is configured as a pouch.
 7. The packaging container of claim 1, wherein the said corrugated component defines an outer packaging container having an inner surface and an outer surface.
 8. The packaging container of claim 6, wherein said first cohesive coating is positioned on said inner surface of said outer packaging container.
 9. The packaging container of claim 1 further comprising an outer packaging container and said corrugated component is an insert that is sized and configured for placement within said outer packaging container.
 10. The packaging container of claim 9 further comprising a support that is cohered to said insert.
 11. A shipping box comprising: a plurality of walls formed of a corrugated material, said corrugated material comprising at least two liners and at least one medium positioned between said at least two liners, a portion of at least one of said plurality of walls being treated with a cohesive coating; and an insert that is sized and configured for placement within said shipping box, said insert being formed of a second corrugated material, said second corrugated material comprising at least two liners and at least one medium disposed between said at least two liners, said insert having a portion thereof treated with a cohesive coating that is complementary to said cohesive coating of said shipping box; wherein said cohesive coating of said insert is placed for contact with said cohesive coating on said shipping box such that said insert can be removably secured in position relative to said shipping box and said insert can be repositioned within said shipping box without destroying either said shipping box or said insert.
 12. The shipping box of claim 11, further comprising a support that is treated with a cohesive coating complementary to said cohesive coatings of said shipping box and said insert and said support being in contact with said insert such that said cohesive coating of said support is in contact with said cohesive coating of said insert
 13. The shipping box of claim 11 further comprising a film that comprises a cohesive coating, said film being in contact with said insert such that said cohesive coating of said film coheres with said cohesive coating of said insert.
 14. The shipping box of claim 11 further comprising a product having a cohesive coating and said product being cohered to one of said insert and said shipping box.
 15. A method of preparing a packaging container for shipment or transportation of the packaging container with a product therein, the method comprising: providing a packaging container having an inner portion thereof treated with a cohesive coating; providing a packaging material having a portion thereof treated with a cohesive coating that is configured to cohere with said cohesive coating of said packaging container; and detachably cohering said packaging material to said packaging container by contacting a portion of said cohesive coating on said packaging material with a portion of said cohesive coating on said packaging container such that said packaging material coheres with said packaging container.
 16. The method of claim 15, further comprising placing a product within said packaging container such that said packaging material limits movement of said product within said packaging container.
 17. The method of claim 15, wherein providing a packaging container having an inner portion thereof treated with a cohesive coating comprises providing a liner with a portion thereof treated with a cohesive coating.
 18. The method of claim 15, wherein providing a packaging material having a portion thereof treated with the cohesive coating comprises spraying said cohesive coating onto said packaging material. 